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Hydraulic & Electro-HydraulicModulating Control
Keeping the World Flowing
ACS Range
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Hydraulic & Electro-Hydraulic Modulating Control2
RELIABILITY IN FLOW CONTROL
CRITICAL APPLICATIONS
RELIABLE OPERATION WHEN IT MATTERS
Assured reliability for critical applications and environments.
Whether used 24/7 or very infrequently, Rotork products will operate reliably and efficiently when called upon.
LOW COST OF OWNERSHIP
Long-term reliability prolongs service life, reducing long term cost of ownership and providing greater efficiency to process and plant.
QUALITY-DRIVEN GLOBAL MANUFACTURING
Rotork products are designed with 60 years of industry and application knowledge.
Research and development across all our facilities ensures cutting edge products are available for every application.
CUSTOMER-FOCUSED SERVICE WORLDWIDE SUPPORT
Rotork focus on solving customer challenges and developing new solutions, from initial enquiry through to product installation, long-term after-sales care and client support programmes.
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Keeping the World Flowing 3
CORPORATE SOCIAL RESPONSIBILITY
Rotork believes that being a responsible business leads to being the best business.
We are socially, ethically, environmentally responsible and committed to embedding CSR across all our processes and ways of working.
COMPREHENSIVE PRODUCT RANGE SERVING MULTIPLE INDUSTRIES
Rotork products and services are used in the Power, Oil & Gas, Water & Waste Water, HVAC, Marine, Mining, Food & Beverage, Pharmaceutical and Chemical industries around the world to improve efficiency, assure safety and protect the environment.
MARKET LEADER TECHNICAL INNOVATOR
The recognised market leader for sixty years.
Our customers have relied upon Rotork for innovative solutions to safely manage the flow of liquids, gases and powders.
GLOBAL PRESENCE LOCAL SERVICE
Global company with local support.
Manufacturing sites, offices and Centres of Excellence throughout the world provide unrivalled customer services and fast delivery.
Hydraulic & Electro-Hydraulic Modulating Control
Section Page
Rotork 2
Introduction 4
Position Control Options - Ring Main Systems 6
Single-acting Fail Closed / Fail Open Position 8
Positional Control Options – Self Contained 10
Section Page
Stepping Positional Control 12
Standard Design Features 13
Electro-Hydraulic Actuation – Coding System 14
Client Support and Site Services 15
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Hydraulic & Electro-Hydraulic Modulating Control4
Introduction
As specialist manufacturers of electro-hydraulic actuation and control equipment we offer comprehensive, purpose designed, engineered and manufactured solutions for the operation of choke and control valves for on-shore and off-shore installations.
The Actuator Control Systems range of hydraulic Modulating Control Systems has been manufactured and supplied into the oil & gas and associated industries for over 35 years.
The range of products is designed, engineered and manufactured to meet the stringent specifications and reliability demanded for application in world-wide locations.
Certification Options Available
xUL ATEX(GOST R)
N
Established in the Oil & Gas Industry with Proven Safety and Reliability
Ease of Setup and Operation
Industry Leading Safety and Reliability
Asset Management and Datalogging
Global Sales and Support
Hazardous Area Operation in Harsh Environmental Conditions
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Keeping the World Flowing 5
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Expertise and knowledge of every aspect of flow control.
Predicitve maintenance programmes and comprehensive customer services.
Health checks and performance analysis for optimum plant performance.
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Hydraulic & Electro-Hydraulic Modulating Control6
Position Control Options - Ring Main Systems
These systems offer a solution for off-shore installations and applications where an hydraulic ring main is available. Actuators are sized to meet with specific hydraulic pressures and types of hydraulic fluid and provide fail-safe stayput fixed position in the event of power failure.
Features
• Centralised hydraulic supply
• Pressure range 50-350 bar
• Hydraulic fluids: Mineral oils, water based and glycols or synthetic types
• Leak tight hydraulic controls with zero leakage / consumption when valve in position
• Positive control for opening, closing and positioning
• Interface to suit valve top works arrangement
• Local manual operation to position valve in event of system failure
Double-acting Fail Fixed Position
• Modulating position control
• Adjustable opening and closing speeds (also refer to stepping option)
• Fail position - Fail last 'Stayput' on
• Loss of hydraulic supply
• Loss of electrical supply
• Loss of command signal
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Keeping the World Flowing 7
Position Control Options - Ring Main Systems
Fail 'Stayput' control system complete with manual override and thermal relief
P
T
11
1
14
10
7
8a
2
Valve Close
Valve Open
3
SET @ 350 BAR
4
6
5
13
12
9
PRESSURE
RETURN
9
CABINET
MANIFOLD
15
1/2"NPT
1/2"NPT
17
16
8b
8c
Item Description1 Linear actuator (double acting)2 Linear potentiometer3 Speed control (valve open)4 Speed control (valve close)5 Solenoid valve (valve to open)6 Solenoid valve (valve to close)7 Pressure filter and 'pop up' indicator8A, 8B, 8C Check valve9 System isolating valve
Item Description10 Pressure gauge11 Oil reservoir with flexible separator12 Back pressure valve13 Hand pump14 Thermal relief valve15 SMAR position transmitter16 Isolating valve17 Isolating valve
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Hydraulic & Electro-Hydraulic Modulating Control8
Single-acting Fail Closed / Fail Open Position
These systems offer a solution for off-shore installations and applications where an hydraulic ring main is available. Actuators are sized to meet with specific hydraulic pressures and types of hydraulic fluid and to provide fail-safe action for closing or opening the valve by a mechanical spring in the event of power failure.
Features
• Modulating positional control
• Adjustable opening and closing speeds (also refer to stepping option)
• Fail position - Fail closed,Fail open or Fail last
• Fail position achieved by integral mechanical spring with installed load to provide fail condition on -
• Loss of hydraulic supply
• Loss of electrical supply
• Loss of command signal
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Keeping the World Flowing 9
Single-acting Fail Closed / Fail Open Position
Spring fail (to close) control system
1
6
4
5
7
11
VALVEOPEN
CLOSEDVALVE
3
1/2"NPT
89
1/2" NPT
2
10
12
RETURN
SUPPLY
13
14
3
Actuator drain line incorporatedfor mineral oil hydraulic systems
Item Description Material1 Linear actuator (single acting)
spring to closePainted carbon steel
2 Linear potentiometer 316Ss3 System isolating valve 316Ss4 Speed control open 316Ss5 Speed control closed 316Ss6 Solenoid control with man override (open) 316Ss7 Solenoid control with man override (closed) 316Ss8 Pressure filter with pop up indicator 316Ss9 Pressure gauge 316Ss10 ESD valve (loss of hydraulic pressure) 316Ss11 Back pressure check valve 316Ss12 Pressure gauge (tank press) 316Ss13 Check valve 316Ss14 Speed control 316Ss
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Hydraulic & Electro-Hydraulic Modulating Control10
Positional Control Options – Self Contained
These systems offer a solution for on-shore pipelines and applications where no hydraulic ring main is available. They require an electrical supply and a control command signal 4-20 mA. All features that are offered with ring main systems are available with these self-contained units.
Available in double-acting control and single-acting spring to fail-safe control options with stepping action if required.
Generally all system components are mounted to the actuator assembly to form a compact solution for mounting directly on to the control valve.
Where valves are of smaller sizes and the mounting arrangement not practical, it is possible to supply a free-standing control assembly for mounting locally to the valve with minimum interconnecting hydraulic pipework and wiring.
Typical self-contained control assemblies comprise:
• Hydraulic actuator
• Spring module (for fail to position options)
• Hydraulic power unit
• Hydraulic control module
• Electronic positioner controller / motor starter enclosure
• Pressure control switching
• Hydraulic control switching
• Hydraulic storage accumulator for back-up operation
• Hydraulic hand pump for emergency operation
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Keeping the World Flowing 11
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2
1
8
9
17
15
14
10B
10A
6
19
184A
11B
7
11A16
13
20
21
MANIFOLD10C
22
5C
CLOSED
23
24
4B
12
MTR
CABINET
25
26B
26A 3
5A5B
Positional Control Options – Self Contained
Self Contained - Spring Close System - Linear Actuator (shown in close position)
Item Description1 Linear actuator (single acting) spring close2 Linear potentiometer (simple apparatus)3 Dual pressure filter with pop up indicator4A,4B Suction strainer5A,5B,5C Isolating valve6 EExd MOTORISED PUMP ASS,Y7 Hand pump (manual overide)8 EEmxe solenoid control (valve open)9 EEmxe solenoid control (valve closed)10A, 10B, 10C Check valve11a EExd pressure switch (pump start) PS211b EExd pressure switch (pump stop) PS112 Pressure relief valve13 Pressure gauge
Item Description14 Accumulator15 Accumulator discharge valve16 EExd pressure switch ps3 (low pressure alarm)17 Accumulator isolation18 EExd oil temperature probe19 EExd oil level switch optional20 Oil level sight gauge21 Oil filler22 EExd oil heater23 Speed control (valve open)24 Speed control (valve closed)25 Smart position transmitter26A Proximity switch close (EExia)26B Proximity switch open (EExia)
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Hydraulic & Electro-Hydraulic Modulating Control12
Stepping Positional Control
Valve Operating Speed
20 Seconds (typical non-stepping) Up to 60 minutes 4 mA
20 mA
Adjustable Dwell Period (Typically 1-30 secs)
Adjustable Step Size (Typically 1% (40 msec)
Closed
Open
Normal Stepping
100
80
60
40
20
0
Perc
ent
%The electro-hydraulic stepping actuator provides a low-cost effective alternative solution to the mechanical ratchet style mechanisms that are occasionally used for choke control.
This feature may be incorporated in all versions of hydraulic and electro-hydraulic modulating control options.
The positioner controller may be set in the stepping mode either locally or remotely and causes the valve position to change in a series of steps in accordance with command signal change and achieve the desired position for the process. The size of the steps and the dwell time between steps are adjustable to meet the operational control requirements.
Typical stepping actuator assembly with fail spring close action. Typical stepping actuator assembly with double acting fail stayput action.
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Keeping the World Flowing 13
Standard Design Features
Hydraulic Actuators
• Type – Double-acting and single-acting - self contained
• Construction – Bolted style or tie rod
• Materials of Construction – End caps and tubes - carbon steel with protective plated or painted finish
• Piston Rod – Stainless steel with hard chrome plate
• Tie Rods – Stainless steel
• External Protective Finish – 2-pack epoxy paint system for severe off-shore environment in accordance with project specification
The hydraulic control system comprises manifold mounted control components manufactured in 316 stainless steel. Solenoid valves, speed control valves, hydraulic supply filtration and pressure gauge.
The control manifold assembly may be housed within a 316 stainless steel cabinet to provide additional environmental protection and security.
Suitable for operation with al types of hydraulic fluids -
• Mineral oils
• Synthetic oils
• Biodegradable and water glycol
• Fire resistant types
Hydraulic supply pressure range 50-350 bar.
The actuator assembly includes the valve mounting yoke that is designed to suit individual valve manufacturers standard interface top works.
Electronic Positioners
Generally these are mounted on the actuator assembly requiring a 24 V DC power supply and provide positioning control by a 4-20 mA command signal and providing a 4-20 mA re-transmitted output signal.
EHPC210 Universal Controller
For installation in zone 1 or 2 hazardous areas.
This unit is housed within an Exd enclosure available in 316 stainless steel or coated aluminium and closed coupled to an Exe 316 stainless steel enclosure to facilitate interconnection wiring components on site installation wiring.
The EHPC210 Universal Controller incorporates an LED graphic display with local control setting switch.
• Manual mode for actuator test
• Stepping mode selection
• Fail safe mode selection on loss of power or signal
• HART protocol data on command or retransmitted actual signal
• Configuration by Bluetooth® communication including response tuning, valve position calibration, valve position feedback setting, fault viewing and pump control
• Positional accuracy of control valve from 0.25% with a resolution of 0.1% from the 4-20 mA externally powered command signal
Options Available
• Intrinsically safe galvanic signal isolation command and retransmission
• Integral valve position feedback measurement with direct mounting to actuator
• Alternative power supplies
• Compact positioner EX200 for DIN rail mount into standard Exd enclosure
• Compact positioner IS 200 for DIN rail mount into IP rated enclosure for use in zone 0 hazardous areas
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Hydraulic & Electro-Hydraulic Modulating Control14
Electro-Hydraulic Actuation – Coding System
Example Model Number EHPC210 P 80-36-50 DA FSP SC LS3 MO XXX
ELECTRONIC POSITIONEREHPC210 = Universal positioner controller EX200 = Compact positioner controller Exd IS200 = Compact positioner controller Exia
POSITIONING MODEP = Positioning M = Modulating S = Stepping
ACTUATOR CYLINDER SIZExxx - xxx - xxx = Bore x rod x stroke
(Specify size according to thrust and pressure)
ACTUATOR OPERATIONDA = Double-actingSA = Single-acting
FAIL ACTIONFSP = Fail stayput SFC = Spring fail close SFO = Spring fail open
ACTUATOR SYSTEM TYPERM = Ring main system SC = Self contained system
SPECIAL REQUIREMENTSLS1 = Limit switch open LS2 = Limit switch close LS3 = Limit switch open and close MO = Manual override (hand pump) SMAR = Independent position transmitter XXX = Other special features
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Keeping the World Flowing 15
Client Support and Site Services
Rotork actuators are recognised as the best in the world for reliability and safety in the most demanding applications. To maintain this hard-earned leadership position, Rotork Site Services is committed to helping clients to maximise the continuous, fault-free operation and working life of all their actuators.
With established operations and worldwide service centres we are able to offer same-day or next-day service to all our customers. Our Rotork factory trained engineers have skills in both multi-purpose and industry specific applications and carry with them spare parts and specialist test equipment. Our operations utilise a documented Quality Management system established in accordance with ISO9001.
Rotork Site Services aims to be your number one choice for taking care of fault diagnosis, service repairs, scheduled maintenance and system integration needs.
Visit www.rotork.com to identify your nearest Rotork Site Services centre.
Global Service and Support
Rotork understand the value of prompt and punctual customer site services and aim to supply our customers with superior flow control solutions, by providing high quality, innovative products and superior service – on time, every time.
Whether you have an actuator requiring on-site servicing, a custom design service requirement or a new actuator installation, we can deliver the fastest turnaround with the least plant disruption.
Accreditation and Assurance
Rotork Site Services is accredited with all major safety authorities around the world, providing our clients with reassurance and peace of mind.
Rotork's engineering teams are experts in the design and implementation of actuation solutions for all circumstances and environments. Our knowledge base draws upon previous installations and environmental situations from all around the world.
Our track record of undertaken engineering projects is second to none. Rotork is trusted by major utility and industrial companies throughout the world to design, install and maintain their actuation stock. We keep their plants operating at peak efficiency, helping them to be more profitable and at the same time meet ever tightening industry watchdog requirements.
We have the knowledge and expertise to design, build and install any standard or custom installation for you, anywhere throughout the world.
Asset Management
Rotork is a corporate member of the Institute of Asset Management, the professional body for whole life management of physical assets.
Giving You Peace of Mind, Guaranteed Quality and
Improving Your Site Efficiency
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PUB025-004-00Issue 05/16
Rotork plcBrassmill Lane, Bath, UK
tel +44 (0)1225 733200fax +44 (0)1225 333467email [email protected]
www.rotork.com
A full listing of our worldwide sales and service network is available on our website.
As part of a process of on-going product development, Rotork reserves the right to amend and change specifications without prior notice. Published data may be subject to change. For the very latest version release, visit our website at www.rotork.com
The name Rotork is a registered trademark. Rotork recognises all registered trademarks. The Bluetooth® word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of such marks by Rotork is under license. Published and produced in the UK by Rotork Controls Limited. POWTC0516
Rotork is a corporate member of the Institute of Asset Management
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